Barrier film and laminated material, container for wrapping and image display medium using the same, and manufacturing method for barrier film

ABSTRACT

An object of the present invention is to provide a barrier film having the extremely high barrier property and the better transparency, a method for manufacturing the same, and a laminated material, a container for wrapping and an image displaying medium using the barrier film. According to the present invention, there is provided a barrier film provided with a barrier layer on at least one surface of a substrate film, wherein the barrier layer is a silicon oxide film having an atomic ratio in a range of Si:O:C=100:140 to 170:20 to 40, peak position of infrared-ray absorption due to Si—O—Si stretching vibration between 1060 to 1090 cm −1 , a film density in a range of 2.6 to 2.8 g/cm 3 , and a distance between grains of 30 nm or shorter. Still more, there is provided a barrier film provided with a barrier layer on at least one surface of a substrate film, has a composition wherein the barrier layer is a silicon oxi-nitride film, and the silicon oxi-nitride film has an atomic ratio in a range of Si:O:N:C=100:60 to 90:60 to 90:20 to 40, a maximum peak of infrared-ray absorption due to Si—O stretching vibration and Si—N stretching vibration is in a range of 820 to 930 cm −1 , a film density is in a range of 2.9 to 3.2 g/cm 3 , and a distance between grains is 30 nm or shorter.

CROSS REFERENCE TO RELATED APPLICATION

This application is a Divisional of U.S. patent application Ser. No.10/417,489, now abandoned entitled “BARRIER FILM AND LAMINATED MATERIAL,CONTAINER FOR WRAPPING AND IMAGE DISPLAY MEDIUM USING THE SAME, ANDMANUFACTURING METHOD FOR BARRIER FILM”, filed Apr. 17, 2003 which claimspriority of Japanese patent application serial number 2002-115774, filedApr. 18, 2002 and Japanese patent application serial number 2002-115775,filed Apr. 18, 2002.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a barrier film having the extremelyhigh barrier property which is used as a wrapping material for foods,medical products and the like, a packaging material for electronicdevices and the like, or a substrate material, a method formanufacturing the same, and a laminated material, a container forwrapping and an image displaying medium using this barrier film.

2. Description of the Related Art

Conventionally, as a wrapping material having the barrier property to anoxygen gas and water vapor, and the better storage suitability forfoods, medical products and the like, various materials have beendeveloped and proposed, such as a barrier film having a composition inwhich a coating layer of polyvinilidene chloride or an ethylene vinylalcohol copolymer is provided on a flexible plastic substrate.

However, in these barrier films, there is a problem that the barrierproperty to oxygen and water vapor is not sufficient, and the barrierproperty is remarkably reduced, in particular, at sterilizationtreatment at a high temperature. Further, a barrier film with a coatinglayer of polyvinilidene chloride provided thereon generates harmfuldioxin at burning, and adverse effect on the environment is concerned.

Therefore, recently, a barrier film having a composition of an inorganicoxide deposition film such as silicon oxide, aluminium oxide and thelike is provided on a substrate film, has been proposed. In addition,lamination, of a resin layer comprising an epoxy resin or a mixturethereof with the above-mentioned deposition film, is proposed (JP-A8-164595).

On the other hand, in an electronic device, for example, in an imagedisplaying device such as flexible display, when a barrier film is usedas a substrate for a plastic film base which is a substitute for a glasssubstrate, or when a barrier film is used as a cover film for a solarcell module, the higher barrier property as compared with the barrierproperty required in utility of the conventional wrapping (e.g. anoxygen transmission rate is 1.0 cc/m²/day·atm or less, a water vaportransmission rate is 1.0 g/m²/day or less) is required to a barrierfilm. In addition, the heat resistance and the chemical resistance suchas resistance to a high temperature at preparation of a display elementand various treating chemicals are required to a barrier film and,further, also after the barrier film is made into products, it isrequired to maintain a high barrier property under the severeenvironment such as a resistance to wet heat test.

The conventional barrier film with an inorganic oxide deposition filmsuch as silicon oxide, aluminium oxide and the like provided thereon isexcellent in the transparency, and has little influence on theenvironment, and an its demand for a wrapping material and the like isgreatly expected. However, the barrier property of these barrier filmsis still lower as compared with a laminated material for wrapping usingan aluminium foil, and there is a problem in serviceability in use in anelectronic device requiring the particularly high barrier property (e.g.an oxygen transmission rate is 0.1 cc/m²/day·atm or less, a water vaportransmission rate is 0.1 g/m²/day or less).

SUMMARY OF THE INVENTION

The present invention has been achieved in order to solve the aboveproblems. It is an object of this invention to provide a barrier filmhaving the extremely high barrier property and also a bettertransparency, a method for manufacturing the same, and a laminatedmaterial, a container for wrapping and an image displaying medium usingthe barrier film.

In order to achieve the above object, in the first embodiment of thepresent invention, a barrier film provided with a barrier layer on atleast one surface of a substrate film, has a composition wherein thebarrier layer is a silicon oxide film, and the silicon oxide film has anatomic ratio in a range of Si:O:C=100:140 to 170:20 to 40, peak positionof infrared-ray absorption due to Si—O—Si stretching vibration isbetween 1060 to 1090 cm⁻¹, a film density is in a range of 2.6 to 2.8g/cm⁻¹, and a distance between grains is 30 nm or shorter.

In other aspect of the present invention, the barrier film has acomposition wherein the barrier layer is provided on the substrate filmvia a resin layer.

In other aspect of the present invention, the barrier film has acomposition wherein a resin layer is provided on the barrier layer.

In other aspect of the present invention, the barrier film has acomposition wherein oxygen transmission rate thereof is 0.1cc/m²/day·atm or less, and water vapor transmission rate thereof is 0.1g/m²/day or less.

In the present invention, a laminated material has a composition whereina heat sealable resin layer is provided on at least one surface of theabove barrier film.

In the present invention, a container for wrapping has a compositionwherein the container is obtained by making a bag or a can by heatanastomosing the heat sealable resin layer using the above laminatedmaterial.

In addition, in the present invention, a laminated material has acomposition wherein a conductive layer is provided on at least onesurface of the above barrier film.

In the present invention, an image displaying medium has a compositionwherein an image displaying layer is provided on the conductive layerusing the above laminated material as a substrate.

In the present invention, a method for manufacturing a barrier filmcomprises forming a silicon oxide film on a substrate film as a barrierlayer wherein the silicon oxide film has an atomic ratio in a range ofSi:O:C=100:140 to 170:20 to 40, peak position of infrared-ray absorptiondue to Si—O—Si stretching vibration is between 1060 to 1090 cm⁻¹, a filmdensity is in a range of 2.6 to 2.8 g/cm³ and a distance between grainsis 30 nm or shorter, by using either of silicon having a sintereddensity of 80% or higher or silicon monoxide having a sintered densityof 80% or higher as a target in the presence of an oxygen gas by asputtering method.

In other aspect of the present invention, the method for manufacturing abarrier film has a composition wherein the sputtering method is any of aRF sputtering method and a dual magnetron sputtering method.

In other aspect of the present invention, the method for manufacturing abarrier film has a composition wherein a resin layer is provided on thesubstrate film in advance, and the barrier layer is formed on the resinlayer.

In such the present invention, by rendering an atomic ratio in a siliconoxide film, a peak position of infrared-ray absorption due to Si—O—Sistretching vibrations, a film density and a distance between grains inspecified ranges, the siliconoxide film becomes to have a compactstructure, and a barrier layer comprising this silicon oxide film givesa high barrier property and transparency to the barrier film.

In addition, in the second embodiment of the present invention, abarrier film provided with a barrier layer on at least one surface of asubstrate film, has a composition wherein the barrier layer is a siliconoxi-nitride film, and the silicon oxi-nitride film has an atomic ratioin a range of Si:O:N:C=100:60 to 90:60 to 90:20 to 40, a maximum peak ofinfrared-ray absorption due to Si—O stretching vibration and Si—Nstretching vibration is in a range of 820 to 930 cm⁻¹, a film density isin a range of 2.9 to 3.2 g/cm³, and a distance between grains is 30 nmor shorter.

In other aspect of the present invention, the barrier film has acomposition wherein the barrier layer is provided on the substrate filmvia a resin layer.

In other aspect of the present invention, the barrier film has acomposition wherein a resin layer is provided on the barrier layer.

In other aspect of the present invention, the barrier film has acomposition wherein oxygen transmission rate thereof is 0.1cc/m²/day·atm or less, and water vapor transmission rate thereof is 0.1g/m²/day or less.

In the present invention, a laminated material has a composition whereina heat sealable resin layer is provided on at least one surface of theabove barrier film.

In the present invention, a container for wrapping has a compositionwherein the container is obtained by making a bag or a can by heatanastomosing the heat sealable resin layer using the above laminatedmaterial.

In addition, in the present invention, a laminated material has acomposition wherein a conductive layer is provided on at least onesurface of the above barrier film.

In the present invention, an image displaying medium has a compositionwherein an image displaying layer is provided on the conductive layerusing the above laminated material as a substrate.

In the present invention, a method for manufacturing a barrier filmcomprises forming a silicon oxi-nitride film on a substrate film as abarrier layer wherein the siliconoxi-nitride film has an atomic ratio ina range of Si:O:N:C=100:60 to 90:60 to 90:20 to 40, a maximum peak ofinfrared-ray absorption due to Si—O stretching vibration and Si—Nstretching vibration is in a range of 820 to 930 cm⁻¹, a film density isin a range of 2.9 to 3.2 g/cm³ and a distance between grains is 30 nm orshorter, by using silicon nitride (Si₃N₄) having a sintered density of60% or higher as a target in the presence of an oxygen gas by asputtering method.

In other aspect of the present invention, the method for manufacturing abarrier film has a composition wherein the sputtering method is a RFsputtering method.

A method for manufacturing a barrier film of the present inventioncomprises forming, as a barrier layer, a silicon oxi-nitride film havingan atomic ratio in a range of Si:O:N:C=100:60 to 90:60 to 90:20 to 40, amaximum peak of infrared-ray absorption due to Si—O stretching vibrationand Si—N stretching vibration in a range of 820 to 930 cm⁻¹, a filmdensity in a range of 2.9 to 3.2 g/cm³, and a distance between grains of30 nm or shorter, on a substrate film, using silicon having an electricresistivity of 0.2 Ωcm or less as a target in the presence of an oxygengas and a nitrogen gas by a sputtering method.

In other aspect of the present invention, the sputtering method is adual magnetron sputtering method or a RF sputtering method.

In other aspect of the present invention, the method for manufacturing abarrier film has a composition wherein a resin layer is provided on thesubstrate film in advance, and the barrier layer is formed on the resinlayer.

In such the present invention, by rendering an atomic ratio in a siliconoxi-nitride film, a maximum peak of an infrared-ray absorbing band dueto Si—O stretching vibration and Si—N stretching vibration, a filmdensity and a distance between grains in specified ranges, the siliconoxi-nitride film becomes to have a compact structure, and a barrierlayer comprising this silicon oxi-nitride film gives a high barrierproperty and transparency to the barrier film.

As described above in detail, according to the present invention, abarrier film is provided with a barrier layer on at least one surface ofa substrate film, this barrier layer is a silicon oxide film having anatomic ratio in a range of Si:O:C=100:140 to 170:20 to 40, peak positionof infrared-ray absorption due to Si—O—Si stretching vibration isbetween 1060 to 1090 cm⁻¹, a film density is in a range of 2.6 to 2.8g/cm³, and a distance between grains is 30 nm or shorter, therefore, thebarrier layer has a compact structure, thereby, a barrier film havingthe extremely high barrier property and the excellent transparencybecomes possible.

Still more, according to the present invention, a barrier film isprovided with a barrier layer on at least one surface of a substratefilm, this barrier layer is a silicon oxi-nitride film having an atomicratio in a range of Si:O:N:C=100:60 to 90:60 to 90:20 to 40, a maximumpeak of infrared-ray absorption due to Si—O stretching vibration andSi—N stretching vibration is in a range of 820 to 930 cm⁻¹, a filmdensity is in a range of 2.9 to 3.2 g/cm³, and a distance between grainsis 30 nm or shorter, therefore, the barrier layer has a compactstructure, thereby, a barrier film having the extremely high barrierproperty and the excellent transparency becomes possible.

In addition, by intervening a resin layer between a substrate film and abarrier layer, a dimensional change in a substrate film at formation ofa barrier layer is prevented, and the adhesion between a substrate filmand a barrier layer becomes higher, and, thus, a barrier film having aimproved barrier property becomes possible.

Further, by provision of a resin layer on a barrier layer, this resinlayer functions as a protective film and gives the heat resistance, thechemical resistance and the weather resistance to a barrier film and, atthe same time, even when a barrier layer has a defective part, byfilling the part, it becomes possible to maintain the high barrierproperty.

According to the method for manufacturing of the present invention, thebarrier film of the present invention can be manufactured simply, andthe barrier film of the present invention can be preferably used inutility requiring the extremely high barrier property, for example,wrapping materials for foods, medical products and the like, packagingmaterials such as electronic devices, and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic cross-sectional view showing one embodiment of abarrier film of the present invention.

FIG. 2 is a schematic cross-sectional view showing another embodiment ofa barrier film of the present invention.

FIG. 3 is a schematic cross-sectional view showing another embodiment ofa barrier film of the present invention.

FIG. 4 is a schematic cross-sectional view showing one embodiment of alaminated material using a barrier film of the present invention.

FIG. 5 is a schematic cross-sectional view showing another embodiment ofa laminated material using a barrier film of the present invention.

FIG. 6 is a schematic cross-sectional view showing another embodiment ofa laminated material using a barrier film of the present invention.

FIG. 7 is a perspective view showing one embodiment of a container forwrapping using a barrier film of the present invention.

FIG. 8 is a perspective view showing another embodiment of a containerfor wrapping using a barrier film of the present invention.

FIG. 9 is a plane view of a blank plate used in manufacturing thecontainer for wrapping shown in FIG. 8.

FIG. 10 is a schematic cross-sectional view showing another embodimentof a laminated material using a barrier film of the present invention.

FIG. 11 is a schematic view showing a configuration of a dual-cathodetype sputtering apparatus used in example 3.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Next, embodiments of the present invention will be explained byreferring to the drawings.

(Barrier Film)

FIG. 1 is a schematic cross-sectional view showing one embodiment of abarrier film of the present invention. In FIG. 1, a barrier film 1 isprovided with a substrate film 2, and a barrier layer 3 formed on onesurface of this substrate film 2. Still more, a barrier film 1 of thepresent invention may be provided with a barrier layer 3 on bothsurfaces of a substrate film 2.

FIG. 2 is a schematic cross-sectional view showing another embodiment ofa barrier film of the present invention. In FIG. 2, a barrier film 11 isprovided with a substrate film 12, and a barrier layer 13 formed on onesurface of this substrate film 12 via a resin layer 14. Still more, abarrier film 11 of the present invention may be such that a resin layer14 and a barrier layer 13 are laminated on both surfaces of a substratefilm 12. Still more, a barrier film 11 may be formed by repeatinglamination of a resin layer 14 and a barrier layer 13 for two or moretimes.

In addition, FIG. 3 is a schematic cross-sectional view showing anotherembodiment of a barrier film of the present invention. In FIG. 3, abarrier film 21 is provided with a substrate film 22, and a barrierlayer 23 and a resin layer 24 which are laminated in this order on onesurface of this substrate film 22, Still more, a barrier film 21 of thepresent invention may be such that a barrier layer 23 and a resin layer24 are laminated in this order on both surfaces of a substrate film 22.Still more, a barrier film 21 may be formed by repeating lamination of abarrier layer 23 and a resin layer 24 for two or more times.

Then, each constituent member of the above-mentioned barrier film of thepresent invention will be explained.

(Substrate Film)

A substrate film constituting a barrier film of the present invention isnot particularly limited as far as the film can retain a barrier layer,or a barrier layer and a resin layer, and can be appropriately selecteddepending on intended use of a barrier film. Specifically, as asubstrate film, oriented (monoaxial or biaxial) or non-oriented flexibletransparent resin films of polyolefin series resins such aspolyethylene, polypropylene, polybutene and the like; amorphouspolyolefin series resins such as cyclic polyolefin and the like; (meth)acrylic series resins; polyvinyl chloride series resins; polystyreneseries resins; saponified ethylene-vinyl acetate copolymer; polyvinylalcohol series resins such as polyvinyl alcohol resin, ethylene-vinylalcohol copolymer and the like; polycarbonate series resins; polyvinylbutyrate resins; polyalylate resins; fluorine series resins such asethylene-ethylene tetrafluoride copolymer, ethylene chloridetrifluoride, ethylene tetrafluoride-perfluoroalkyl vinyl ethercopolymer, vinylidene fluoride, vinyl fluoride,perfluoro-perfluoropropylene-perfluorovinyl ether copolymer and thelike; polyvinyl acetate series resins; acetal series resins; polyesterseries resins such as polyethylene terephthalate (PET), polyethylene2,6-naphthlate (PEN) and the like; polyamide series resins such as nylon(trade name) 6, nylon (trade name) 12, copolymerized nylon (trade name)and the like; polyimide resins; polyetherimide resins; polysulfoneresins; polyethersulfone resins; polyether ether ketone resins can beused. A thickness of a substrate film can be appropriately set in arange of 5 to 500 μm, preferably 10 to 200 μm.

(Barrier Layer)

A barrier layer constituting a barrier film of the first embodiment ofthe present invention is a silicon oxide film having an atomic ratio ina range of Si:O:C=100:140 to 170:20 to 40. In this silicon oxide film,peak position of infrared-ray absorption due to Si—O—Si stretchingvibration is between 1060 to 1090 cm⁻¹, a film density is in a range of2.6 to 2.8 g/cm³, preferably 2.7 to 2.8 g/cm³, and a distance betweengrains is 30 nm or less, preferably in a range of 10 to 30 nm, morepreferably 10 to 20 nm. A distance between grains reflects a growingnucleus distribution density at preparation of a silicon oxide film and,when there are many growing nuclei, and a film is manufacturedelaborately, micro crystals (grains) cover a substrate film or a resinlayer without any gap.

When an atomic ratio, a peak position of infrared-ray absorption due toSi—O—Si stretching vibration, a film density and a distance betweengrains of a silicon oxide film which is a barrier layer are out of theabove-mentioned ranges, elaboration of a silicon oxide film is reduced,the extremely high barrier property (indicates an oxygen transmissionrate is 0.1 cc/m²/day·atm or less, a water vapor transmission rate isaround 0.1 g/m²/day or less) can not be obtained, a silicon oxide filmbecomes hard and brittle, and the durability is reduced, being notpreferable.

Herein, in the present invention, the above-mentioned an atomic ratio ismeasured by a photoelectron spectroscopy (Electron Spectroscopy forChemical Analysis; ESCA). In addition, the infrared-ray absorption dueto Si—O—Si stretching vibration is measured using a Fourier transforminfrared spectrometer (Herschel FT-IR-610 manufactured by JASCOCorporation) provided with a multiple reflection (Attenuated TotalReflection; ATR) measuring apparatus. In addition, the above-mentionedfilm density is measured with a X-ray reflectivity measuring apparatus(ATX-E manufactured by Rigaku Corporation). Further, the above-mentioneddistance between grains is measured by using an atom force microscope(AEM) (Nano ScopeIII manufactured by Digital Instruments).

Such the barrier layer can be formed by a sputtering method such as a RFsputtering method, a dual magnetron sputtering method and the like. Athickness of a barrier layer can be appropriately set in a range of 5 to500 nm, preferably 10 to 100 nm. When a thickness of a barrier layer isless than 5 nm, the extremely high barrier property (indicates an oxygentransmission rate is 0.1 cc/m²/day·atm or less, and a water vaportransmission rate is around 0.1 g/m²/day or less) can not be manifested.On the other hand, when a thickness of a barrier layer exceeds 500 nm, agreat stress is exerted and, when a substrate film is flexible, a crackis easily caused in a barrier layer, the barrier property is reducedand, at the same time, a time necessary for manufacturing a film becomeslonger, being not preferable.

A barrier layer constituting a barrier film of the second embodiment ofthe present invention is a silicon oxi-nitride film having an atomicratio in a range of Si:O:N:C=100:60 to 90:60 to 90:20 to 40. In thissilicon oxi-nitride film, a maximum peak of infrared-ray absorption dueto Si—O stretching vibration and Si—N stretching vibration exists in arange of 820 to 930 cm⁻¹, a film density is in a range of 2.9 to 3.2g/cm³, preferably 3.0 to 3.2 g/cm³, and a distance between grains is 30nm or less, preferably in a range of 10 to 30 nm, more preferably 10 to20 nm. If there are a maximum peak of infrared-ray absorption due toSi—O stretching vibration and a maximum peak of infrared-ray absorptiondue to Si—N stretching vibration, a maximum peak of infrared-rayabsorption due to Si—O stretching vibration and Si—N stretchingvibration indicates the greater peak. And if there is one maximum peakof infrared-ray absorption due to Si—O stretching vibration and Si—Nstretching vibration, it indicates the peak absorption. A distancebetween grains reflects a growing nucleus distribution density atpreparation of a silicon oxi-nitride film and, when there are manygrowing nuclei, and a film is manufactured elaborately, micro crystals(grains) cover a substrate film or a resin layer without any gap.

When an atomic ratio, a maximum peak of an infrared-ray absorbing banddue to Si—O stretching vibration and Si—N stretching vibration, a filmdensity and a distance between grains of a silicon oxi-nitride filmwhich is a barrier layer are out of the above-mentioned ranges,elaboration of a silicon oxi-nitride film is reduced, the extremely highbarrier property (indicates an oxygen transmission rate is 0.1cc/m²/day·atm or less, a water vapor transmission rate is around 0.1g/m²/day or less) can not be obtained, a silicon oxi-nitride filmbecomes hard and brittle, and the durability is reduced, being notpreferable.

Herein, in the present invention, the above-mentioned an atomic ratio ismeasured by a photoelectron spectroscopy (Electron Spectroscopy forChemical Analysis; ESCA). In addition, a maximum peak of theinfrared-ray absorption due to Si—O stretching vibration and Si—Nstretching vibration is measured using a Fourier transform infraredspectrometer (Herschel FT-IR-610 manufactured by JASCO Corporation)provided with a multiple reflection (Attenuated Total Reflection; ATR)measuring apparatus. In addition, the above-mentioned film density ismeasured with a X-ray reflectivity measuring apparatus (ATX-Emanufactured by Rigaku Corporation). Further, the above-mentioneddistance between grains is measured by using an atom force microscope(AEM) (Nano ScopeIII manufactured by Digital Instruments).

Such the barrier layer can be formed by a sputtering method such as a RFsputtering method, a dual magnetron sputtering method and the like. Athickness of a barrier layer can be appropriately set in a range of 5 to500 nm, preferably 10 to 200 nm. When a thickness of a barrier layer isless than 5 nm, the extremely high barrier property (indicates an oxygentransmission rate is 0.1 cc/m²/day·atm or less, and a water vaportransmission rate is around 0.1 g/m²/day or less) can not be manifested.On the other hand, when a thickness of a barrier layer exceeds 500 nm, agreat stress is exerted and, when a substrate film is flexible, a crackis easily caused in a barrier layer, the barrier property is reducedand, at the same time, a time necessary for manufacturing a film becomeslonger, being not preferable.

(Resin Layer)

A resin layer 14 constituting a barrier film 11 of the present inventionis for improving the adhesion between a substrate film 12 and a barrierlayer 13, and for improving the barrier property. In addition, a resinlayer 24 covering a barrier layer 23 functions as a protecting film andis for giving the heat resistance, the chemical resistance and theweather resistance to a barrier film 21 and, at the same time, forimproving the barrier property by filling a defective part even when abarrier layer 23 has the defective part.

Such the resin layer can be formed from one kind, or a combination of 2or more commercially available resin materials such as polyamic acid, apolyethylene resin, a melamine resin, a polyurethaneresin, apolyesterresin, a polyolresin, a polyurea resin, a polyazomethine resin,a polycarbonate resin, a polyacrylate resin, a polystyrene resin, apolyacrylonitrile (PAN) resin, a polyethylene naphthalate (PEN) and thelike, a curing epoxy resin containing a high-molecular weight epoxypolymer which is a polymer of a bifunctional epoxy resin and abifunctional phenols, and a resin material used in the above-mentionedsubstrate film, an anchor coating agent used in a laminated materialdescribed later, an adhesive, a heat sealable resin material and thelike. It is preferable that a thickness of a resin layer isappropriately set depending on a material to be used and, for example,the thickness can be set in a range of around 5 nm to 5×10⁵ nm.

In addition, in the present invention, a non-fibrous inorganic fillerhaving an average particle diameter in a range of 0.8 to 5 μm may becontained in a resin layer. Examples of the non-fibrous inorganic fillerto be used include aluminium hydroxide, magnesium hydroxide, talc,alumina, magnesia, silica, titanium dioxide, clay and the like and, inparticular, sintered clay can be preferably used. Such the inorganicfiller can be contained in a range of 10 to 60% by volume, preferably 25to 45% by weight of a resin layer.

Method for Manufacturing Barrier Film

Next, a method for manufacturing a barrier film of the present inventionwill be explained.

In a method for manufacturing a barrier film of the first embodiment ofthe present invention, a barrier layer is formed by a sputtering method.As a sputtering method, any of a RF sputtering method and a dualmagnetron sputtering method is used. A film is manufactured in thepresence of an oxygen gas using silicon having a sintered density of 80%or greater, or silicon monoxide having a sintered density of 80% orgreater, as a target. By rendering a density of a target 80% or greater,it becomes possible to form an elaborated siliconoxide film. Inaddition, since forming a film by the above-mentioned sputtering methodis a reactive forming of film, control of oxidation degree is easy and,further, by rendering a distance between a target and a material onwhich a film is to be formed, and an input electric power adequate,suitable etching is generated in a material on which a film is to beformed at preparation of a film, and a silicon oxide film can bemanufactured at a high adhesion. And, a material and film manufacturingconditions to be used can be selected so that an atomic ratio in amanufactured silicon oxide film is in a range of Si:O:C=100:140 to170:20 to 40, peak position of infrared-ray absorption due to Si—O—Sistretching vibration is between 1060 to 1090 cm⁻¹, a film density is ina range of 2.6 to 2.8 g/cm³, preferably 2.7 to 2.8 g/cm³, and a distancebetween grains is 30 nm or less, preferably in a range of 10 to 30 nm,more preferably 10 to 20 nm.

In addition, in the case of the above-mentioned barrier films 11 and 21provided with a resin layer as shown in FIG. 2 and FIG. 3, formation ofa resin layer can be performed by a dry forming method by a physicaldeposition method such as previously known vacuum deposition,sputtering, ion plating and the like, a chemical vapor deposition (CVD)method and the like, or a wet forming method of coating by a coatingmethod such as roll coating, gravure coating, knife coating, dippingcoating, spray coating and the like, thereafter, drying to remove asolvent and a diluent. A forming method can be appropriately selecteddepending on a material to be used. Still more, by forming a resin layerby a sputtering method, formation of a barrier layer and formation of aresin layer may be performed by in-line in the same film manufacturingapparatus.

In addition, in a method for manufacturing a barrier film of the secondembodiment of the present invention, a barrier layer is formed by asputtering method. As a sputtering method, any of a RF sputtering methodand a dual magnetron sputtering method is used. A film is manufacturedin the presence of an oxygen gas using silicon nitride (Si₃N₄) having asintered density of 60% or greater, as a target. Usually in forming afilm, nitriding of a film is difficult, but in the above method ofmanufacturing, it makes possible to form silicon oxi-nitride film easilybecause the target itself has Si—N bonding. By rendering a density of atarget 60% or greater, it becomes possible to form an elaborated siliconoxi-nitride film. In addition, since forming a film by theabove-mentioned sputtering method is a reactive forming of film, controlof oxidation degree is easy and, further, by rendering a distancebetween a target and a material on which a film is to be formed, and aninput electric power adequate, suitable etching is generated in amaterial on which a film is to be formed at preparation of a film, and asiliconoxi-nitride film can be manufactured at a high adhesion. And, amaterial and film manufacturing conditions to be used can be selected sothat an atomic ratio in a manufactured silicon oxi-nitride film is in arange of Si:O:N:C=100:60 to 90:60 to 90:20 to 40, a maximum peak ofinfrared-ray absorption due to Si—O stretching vibration and Si—Nstretching vibration is in a range of 820 to 930 cm⁻¹, a film density isin a range of 2.9 to 3.2 g/cm³, preferably 3.0 to 3.2 g/cm³, and adistance between grains is 30 nm or less, preferably in a range of 10 to30 nm, more preferably 10 to 20 nm.

In addition, in a method for manufacturing a barrier film of the presentinvention, film making may be performed by using a dual magnetronsputtering method as a sputtering method and using silicon having anelectric resistivity of 0.1 Ωcm or less as a target in the presence ofan oxygen gas and a nitrogen gas. By rendering an electric resistivityof a target 0.2 Ωcm or less, it becomes possible to form a compactsilicon oxi-nitride film. In addition, since film making is reactivefilm making, it is easy to control an oxidation degree and a nitridingdegree, further, by rendering adequate a distance between a target and amaterial on which a film is to be formed, and an input electric power,adequate etching is produced in a material on which a film is to beformed at film making, and a silicon oxi-nitride film can be made at thehigh adherability. And, a material and film making conditions to be usedare selected so that an atomic ratio of a silicon oxi-nitride film to beformed is in a range of Si:O:N:C=100.60 to 90:60 to 90:20 to 40, amaximum peak of infrared absorption due to Si—O stretching vibration andSi—N stretching vibration is in a range of 820 to 930 cm⁻¹, a filmdensity is in a range of 2.9 to 3.2 g/cm³, preferably 3.0 to 3.2 g/cm³,and a distance between grains is 30 nm or shorter, preferably in a rangeof 10 to 30 nm, more preferably 10 to 20 nm.

In addition, in the case of the above-mentioned barrier films 11 and 21provided with a resin layer as shown in FIG. 2 and FIG. 3, formation ofa resin layer can be performed by a dry forming method by a physicaldeposition method such as previously known vacuum deposition,sputtering, ion plating and the like, a chemical vapor deposition (CVD)method and the like, or a wet forming method of coating by a coatingmethod such as roll coating, gravure coating, knife coating, dippingcoating, spray coating and the like, thereafter, drying to remove asolvent and a diluent. A forming method can be appropriately selecteddepending on a material to be used. Still more, by forming a resin layerby a sputtering method, formation of a barrier layer and formation of aresin layer may be performed by in-line in the same film manufacturingapparatus.

Laminated Material

Next, a laminated material of the present invention will be explained.

FIG. 4 is a schematic cross-sectional view showing an embodiment of alaminated material of the present invention using the above-mentionedbarrier film 1 of the present invention. In FIG. 4, a laminated material31 is provided with a barrier film 1 which is provided with a barrierlayer 3 on one surface of a substrate film 2, and a heat sealable resinlayer 33 formed on a barrier layer 3 of this barrier film 1 via ananchor coating agent layer and/or an adhesive layer 32.

An anchor coating agent layer 32 constituting a laminated material 31can be formed, for example, by using an organic titanium series anchorcoating agent such as alkyl titanate and the like, an isocianate seriesanchor coating agent, a polyethyleneimine series anchor coating agent, apolybutadiene series anchor coating agent or the like. An anchor coatingagent layer 32 can be formed by coating the above-mentioned anchorcoating agent, for example, by the known coating method such as rollcoating, gravure coating, knife coating, dipping coating, spray coatingand the like, and drying to remove a solvent, a diluent and the like. Asan amount of the above-mentioned anchor coating agent to be coated,around 0.1 to 5 g/m² (dry state) is preferable.

In addition, an adhesive layer 32 constituting a laminated material 31can be formed, for example, by using various laminating adhesives suchas solution type, aqueous type, non-solvent type and heat melting typewhich contain, as a main component, a vehicle such as polyurethaneseries, polyester series, polyamide series, epoxy series, poly(meth)acrylic series, polyvinyl acetate series, polyolefin series, casein,wax, ethylene-(meth)acrylic acid copolymer, polybutadiene series and thelike. An adhesive layer 32 can be formed by coating the above-mentionedlaminating adhesive, for example, by a coating method such as rollcoating, gravure coating, knife coating, dipping coating, spray coatingand the like, and drying to remove a solvent, a diluent and the like. Asan amount of the above-mentioned laminating adhesive to be coated,around 0.1 to 5 g/m² (dry state) is preferable.

Examples of a heat sealable resin used in a heat sealable resin layer 33constituting a laminated material 31 include resins which are melted byheat and can be an astomosed to each other. Specifically, aciddenaturated polyolefin resins, polyvinyl acetate series resins,poly(meth)acrylic resins, polyvinyl chloride series resins and the likeobtained by denaturating polyolefin series resins such as low densitypolyethylene, intermediate density polyethylene, high densitypolyethylene, straight chain (linear) low density polyethylene,polypropylene, ethylene-vinyl acetate copolymer, ionomer resin, ethylene-acrylic aid copolymer, ethylene-methacrylic acid copolymer,ethylene-methyl methacrylate copolymer, ethylene-propylene copolymer,methylpentene polymer, polybutene polymer, polyethylene, polypropyleneand the like with unsaturated carboxylic acid such as acrylic acid,methacrylic acid, maleic acid, maleic anhydride, fumaric acid, itaconicacid and the like can be used. The heat sealable resin layer 33 may beformed by coating the above-mentioned heat sealable resin, or may beformed by laminating a film or a sheet comprising the above-mentionedheat sealable resin. A thickness of such the heat sealable resin layer33 can be set in a range of 5 to 300 μm, preferably 10 to 100 μm.

FIG. 5 is a schematic cross-sectional view showing an embodiment of alaminated material of the present invention using the above-mentionedbarrier film 11 of the present invention. In FIG. 5, a laminatedmaterial 41 is provided with a barrier film 11 which is provided with abarrier layer 13 on one surface of a substrate film 12 via a resin layer14, a heat sealable resin layer 43 formed on this barrier layer 13 of abarrier film 11 via an anchor coating agent layer and/or an adhesivelayer 42, and a substrate 44 provided on the other surface (resin layernon-forming surface) of a substrate film 12 of a barrier film 11.

An anchor coating agent layer, an adhesive layer 42 and a heat sealbalelayer 43 constituting a laminated material 41 may be the same as theanchor coating layer, the adhesive layer 32 and the heat sealable resinlayer 33 constituting the above-mentioned laminated layer 31 and,therefore, explanation thereof will be omitted.

As a substrate 44 constituting a laminated material 41, for example,when a laminated material 41 constitutes a container for wrapping, sincea substrate 44 is to be a fundamental material, a film or a sheet of aresin having the excellent mechanical, physical, chemical and otherproperties, in particular, having the strength and the toughness, andheat resistance can be used. Examples thereof include oriented(monoaxial or biaxial) or non-oriented films or sheets of tough resinssuch as a polyester series resin, a polyamide series resin, a polyaramidseries resin, a polyolefin series resin, a polycarbonate series resin, apolystyrene series resin, a polyacetel series resin, a fluorine seriesrein and the like. It is desirable that a thickness of this substrate 44is 5 to 100 μm, preferably around 10 to 50 μm.

In addition, in the present invention, for example, front face printingor rear face printing of a desired printing design such as letter,figure, symbol, design, pattern and the like may be imparted to asubstrate 44 by the conventional printing method. Such the letter andthe like can be recognized visually through a barrier film 11constituting a laminated material 41.

FIG. 6 is a schematic cross-sectional view showing an embodiment of alaminated material of the present invention using the above-mentionedbarrier film 21 of the present invention. In FIG. 6, a laminatedmaterial 51 is provided with a barrier film 21 in which a barrier layer23 and a resin layer 24 are laminated in this order on one surface of asubstrate film 22, a heat sealable resin layer 53 formed on a resinlayer 24 of this barrier film 21 via an anchor coating agent layerand/or an adhesive layer 52, a substrate 54 which is provided on theother surface (barrier layer non-forming surface) of a substrate film 22of a barrier film 21, and a heat sealable resin layer 55 formed on thissubstrate 54.

An anchor coating agent layer, an adhesive layer 52 and heat sealableresin layers 53 and 55 constituting a laminated material 51 may be thesame as the anchor coating agent layer, the adhesive layer 32 and theheat sealable resin layer 33 constituting the above-mentioned laminatedmaterial 31, and a substrate 54 constituting a laminated material 51 maybe the same as the substrate 44 constituting above-mentioned laminatedmaterial 41 and, therefore, the explanation thereof will be omitted.

In addition, in the laminated material of the present invention,further, for example, films or sheets of resins having the barrierproperty to water vapor, water and the like such as low densitypolyethylene, intermediate density polyethylene, high densitypolyethylene, straight chain low density polyethylene, polypropylene,ethylene-propylene copolymer and the like, films or sheets of resinshaving the barrier property to oxygen, water vapor and the like such aspolyvinyl alcohol, saponified ethylene-vinyl acetate copolymer and thelike, or films or sheets of various colored resins having the lightshielding property obtained by adding a colorant such as a pigment andthe like, and other desired additives to a resin, kneading them, andconverting this into a film, may be used.

These materials may be used alone or by combining two or more kinds, anda thickness there of is arbitrary, but is usually 5 to 300 μm,preferably around 10 to 200 μm.

Further, when the laminated material of the preset invention is used inutility of a container for wrapping, since the container for wrapping isusually placed under the physical and chemical severe conditions, thesevere wrapping suitability is required also for a laminated material.Specifically, various conditions such as the deformation preventingstrength, the falling impact strength, the resistance to pin hole, theresistance to heat, the sealability, the quality preserving property,the workability, the hygiene property and others are required and, forthis reason, in the laminated material of the present invention,materials satisfying the above-mentioned various conditions may bearbitrarily selected and used as substrate films 2, 12 and 22,substrates 44 and 54, or other constituent members. Specifically,materials may be used by arbitrarily selecting from films or sheets ofthe known resins such as low density polyethylene, intermediate densitypolyethylene, high density polyethylene, linear low densitypolyethylene, polypropylene, ethylene-propylene copolymer,ethylene-vinyl acetate copolymer, ionomer resin, ethylene-ethyl acrylatecopolymer, ethylene-acrylic acid or methacrylic acid copolymer,methylpentene polymer, polybutene series resin, polyvinyl chlorideseries resin, polyvinyl acetate series resin, poly (meth) acrylic seriesresin, polyacrylonitrile series resin, polystyrene series resin,acrylonitrile-styrene copolymer (AS series resin),acrylonitrile-butadiene-styrene copolymer (ABS series resin), polyesterseries resin, polyamide series resin, polycarbonate series resin,polyvinyl alcohol series resin, saponified ethylene-vinyl acetatecopolymer, fluorine series resin, diene series resin, polyacetal seriesresin, polyurethane series resin, nitrocellulose and the like. Besides,for example, films such as cellophane and the like may be used.

As the above-mentioned film or sheet, any films or sheets which arenon-oriented, or monoaxially or biaxially oriented may be used. Athickness thereof is arbitrary, but may be selected and used from arange of around a few μm to 300 μm, and a laminating position is notparticularly limited. In addition, in the present invention, theabove-mentioned film and sheet may be a membrane having any nature suchas an extruded membrane, an inflated membrane and coated membrane.

The laminated material of the present invention such as theabove-mentioned laminated materials 31, 41 and 51 can be manufactured byusing a method for laminating a normal wrapping material, for example, awet lamination method, a dry lamination method, a non-solvent type drylamination method, an extrusion lamination method, a T die extrusionmolding method, a coextrusion lamination method, an inflation method, acoextrus ion inflation method and the like.

Upon the above-mentioned lamination, if necessary, a film can besubjected to pre-treatment such as corona treatment, ozone treatment andthe like. In addition, anchor coating agents such as isocyanate series(urethane series), polyethyleneimine series, polybutadiene series,organic titanium series and the like, or the known adhesives such aslaminating adhesives such as polyurethane series, polyacrylic series,polyester series, epoxy series, polyvinyl acetate series, celluloseseries and the like can be used.

A combination of barrier films of the present invention used in thelaminated material of the present invention is not limited to examplesshown in the above-mentioned laminated materials 31, 41 and 51, but maybe appropriately set depending on intended use of a laminated material.

Container for Wrapping

Next, a container for wrapping of the present invention will beexplained.

A container for wrapping of the present invention is obtained by makinga bag or a can by heat anastomosing by using the laminated material ofthe present invention.

Specifically, when a container for wrapping is a soft wrapping bag,container for wrappings having a variety forms relating to the presentinvention can be manufactured by folding a heat sealable resin layer ofa laminated material of the present invention facing to each other, orpiling two laminated materials of the present invention, and heatanastomosing a peripheral edge part thereof in the heat seal form suchas side sealing type, two-way sealing type, there-way sealing type,four-way sealing type, envelope making sealing type, butt seaming type(pillow sealing type), ribbed sealing type, flat bottom sealing type,square bottom sealing type, and others, to form a sealed part.

In the above case, heat anastomosing can be performed by the knownmethod such as bar sealing, rotating roll sealing, belt sealing, impulsesealing, high frequency wave sealing, ultrasound sealing and the like.

FIG. 7 is a perspective view showing one embodiment of theabove-mentioned container for wrapping of the present invention. In FIG.7, a container for wrapping 61 is formed by piling one set of laminatedmaterials 31 of the present invention so that the heat sealable resinlayers 33 are facing to each other, and performing heat anastomosing toform sealed part 62 in three ways at a peripheral part in this state.This container for wrapping 61 can be filled with the content through anopening 63 formed on remaining one way at a peripheral part. And, afterthe content is filled therein, the opening 63 is heat anastomosed toform a seald part, whereby, a container for wrapping in which thecontent is filled and packed, is obtained.

A container for wrapping of the present invention may be in the form of,for example, a self-supporting wrapping bag (standing pouch) in additionto the above-mentioned form and, further, a tubular container may bemanufactured by using a laminated material of the present invention.

In addition, in the present invention, an filling port such as one-piecetype, two-piece type and other type, or an opening and closing zippermay be arbitrarily attached to the above-mentioned container forwrapping.

Still more, a container for wrapping of the present invention may bemanufactured into container for a liquid such as brick type, flat typeand gable top type by making a blank plate for manufacturing a desiredcontainer using a laminated material of the present invention, andforming a shell part, a bottom part and a head part employing this blankplate. In addition, as a shape thereof, any shape such as squarecontainer, cylindrical can such as round shape, and the like can bemanufactured.

FIG. 8 is a perspective view showing one embodiment of theabove-mentioned liquid filling paper container which is a container forwrapping of the present invention, and FIG. 9 is a plane view of theblank plate used in the container for wrapping shown in FIG. 8. A blankplate 80 is manufactured by using a laminated material 51 of the presentinvention shown in FIG. 6 and punching out the material so that theplate is provided with a pressing line m, m . . . for bending processingin formation of a container, shell panels 81, 82, 83 and 84 constitutinga shell part 72 of a container 71, top panels 81 a, 82 a, 83 a and 84 aconstituting a top part 73 of a container 71, bottom panels 81 b, 82 b,83 b and 84 b constituting a bottom part 74 of a container 71, and apanel for heat anastomosing 85 for forming a cylinder. This blank plate80 can be processed into a container for wrapping 71 which liquid isfilled and packed bending the plate along a pressing line m, m . . . ,heat anastomosing an inner side of an end of a shell panel 81 and anouter side of a panel for heat anastomosing 85 to form a cylinder,thereafter, bending bottom panels 81 b, 82 b, 83 b and 84 b along apressing line m, m . . . and heat anastomosing the panels, then fillingthis with liquid through an opening at a top part, bending top panels 81a, 82 a, 83 a and 84 a along a pressing line m, m . . . and heatanastomosing the panels.

The container for wrapping of the present invention can be used in avariety of goods such as various foods and beverages, chemicals such asadhesives, pressure-sensitive adhesives and the like, cosmetics, medicalsupply, miscellaneous goods such as chemical warmer and the like, andothers.

Laminated Material

Next, other embodiments of the laminated material of the presentinvention will be explained by way of examples using the above-mentionedbarrier film 1 of the present invention.

FIG. 10 is a schematic cross-sectional view showing other embodiment ofthe laminated material of the present invention. In FIG. 10, a laminatedmaterial 91 is provided with a barrier film 1 which is provided with abarrier layer 3 on one surface of a substrate film 2, and a conductivelayer 92 formed on a barrier layer 3 of this barrier film 1.

A conductive layer 92 constituting a laminated material 91 may be atransparent conductive film such as indium tin oxide (ITO) film. The ITOfilm can be formed by a sputtering method, a PVD method, an ion platingmethod or the like and, in particular, since the ITO film formed by asputtering method is excellent in the inplane uniformity of theconductivity, it is preferably used.

A film thickness of a conductive layer 92 can be appropriately setdepending on a material thereof, use of a laminated material 91 and thelike, and is usually set in a range of 100 to 200 nm. In addition, it ispreferable that a conductive layer 92 has a surface resistance value of0 to 50 Ω/□ and an overall transmittance of 85% or greater.

Such the conductive layer 92 can be used as a transparent electrode fordriving a liquid crystal, for example, in the case of a liquid crystaldisplaying a device.

Image Displaying Medium

An image displaying medium of the present invention uses theabove-mentioned laminated material 91 as a substrate and is providedwith an image displaying layer on a conductive layer 92.

Examples of such the image displaying medium include non-light emittingtype displays for performing display by shutting out the brightness ofbacklight to produce gradation as in a liquid crystal displayingapparatus, and self-light emitting type displays for performing displayby making fluorescent compounds emit with some energy, such as plasmadisplay panel (PDP), field emission display (FED), andelectroluminescense display (EL).

When the image displaying medium of the present invention is a liquidcrystal displaying apparatus, the above-mentioned image displaying layerindicates a liquid crystal layer and, when the medium is a self-lightemitting type display, a fluorescent compound layer having a fluorescentcompound corresponds to above-mentioned image displaying layer.

The present invention is not limited by the above-mentioned respectiveembodiments.

EXAMPLES

The present invention will be explained in more detail by way ofExamples below.

Example 1 Preparation of Barrier Film

A sheet type biaxially oriented polyethyleneterephthalate film (PET filmA4100 manufactured by Toyobo Co., Ltd., thickness 100 μm) having a sizeof 10 cm×10 cm was manufactured as a substrate film, and this substratefilm was placed into a chamber of a batch-type sputtering apparatus(SPF-530H manufactured by Anelva Corporation), using a corona-untreatedside of the film as a surface on which a film is to be formed. Inaddition, silicon (sintered density 90%) as a target material wasmounted in a chamber. A distance between this target and a substratefilm (TS distance) was set to 50 mm.

Then, an oxygen gas (manufactured by Taiyo Toyo Sanso Co., Ltd. (purity99.9995% or larger)) and an argon gas (manufactured by Taiyo Toyo SansoCo., Ltd. (purity 99.9999% or larger)) as a gas to be added at filmformation, were manufactured.

Then, a pressure in a chamber was reduced to ultimate vacuum of 2.5×10⁻³Pa with an oil-sealed rotary vacuum pump and a cryo pump. Then, anoxygen gas at a flow rate of 20 sccm and an argon gas at a flow rate of20 sccm were introduced into a chamber, and a pressure in a chamber wasretained at 0.25 Pa by controlling an opening and closing degree of avalve between a vacuum pump and a chamber, and a barrier layercomprising a silicon oxide film having a thickness of 100 nm was formedon a substrate film at an input electric power of 2 kW by a RF magnetronsputtering method, to obtain a barrier film (Example 1-1). In addition,sccm is an abbreviation of standard cubic centimeter per minute, and isalso the same in Examples and Comparative Examples below.

Components of the silicon oxide film formed in the above were measuredunder the following conditions, and a results are shown in followingTable 1.

Measurement of Components of Silicon Oxide Film

Components were measured with ESCA (ESCA LAB 220i-XL manufactured by VGScientific, England). As a X-ray source, a monochromic Al X-ray sourcehaving the Ag-3d-5/2 peak strength of 300 Kcps to 1 Mcps, and a slithaving a diameter of about 1 mm were used. Measurement was performed inthe state where a detector was set on a normal line of a sample surfaceto be measured, and adequate electrification correction was made.Analysis after measurement was performed by using software Eclipseversion 2.1 attached to the above-mentioned ESCA apparatus and usingpeaks corresponding to the binding energies of Si:2p, C:1s, O:1s. Uponthis, regarding each peak, Shirley's background removal was performed,and sensitivity coefficient correction was performed on each atom (basedon C=1, Si=0.817, O=2.930) regarding each peak area, and an atomic ratiowas obtained. Regarding the resulting atomic ratio, letting a number ofSi atoms to be 100, numbers of O and C atoms which are other componentswere calculated, and was used as a component ratio.

In addition, a peak position of infrared-ray absorption due to Si—O—Sistretching vibration, a film density and a distance between grains of asilicon oxide film formed as described above were measured under thefollowing conditions, respectively, and the results are shown infollowing Table 1.

Measurement of Infrared Absorbing Spectrum

The spectrum was measured using a Fourier transform infraredspectrometer (Herschel FT-IR-manufactured by JASCO Corporation) equippedwith a multiple reflection (ATR) measuring apparatus (ATR-300/Hmanufactured by JASCO Corporation). Measurement was performed using agermanium crystal as a prism at an incident angel of 45°.

Measurement of Film Density

A film density was measured using a X-ray reflectivity measuringapparatus (ATX-E manufactured by Rigaku Corporation) as follows: Thatis, as a X-ray source, a 18 kW X-ray generating apparatus and CuKawavelength λ=1.5405 Å of Cu target was used and, as a monochrometer, aparabolic artificial multi-layered film mirror and Ge (220) monochromiccrystal were used. In addition, the setting conditions were scanningrate: 0.1000°/min, sampling width:0.002°, and scanning range; 0 to4.0000°. Further, a sample was mounted on a substrate folder with amagnet, and 0° positional adjustment was performed by the automaticalignment function of the apparatus. Thereafter, a reflectivity wasmeasured under the above-mentioned setting conditions. The resultingmeasured reflectivity values were analyzed under the conditions offitting area: 0.4° to 4.0° using an analysis software (RGXR) attached tothe above-mentioned X-ray reflectivity measuring apparatus. Upon this, aratio of atoms (Si:O=1:2) of a thin film was input as a fitting initialvalue. A reflectivity was fitted by a non-linear minimum square methodto calculate a film density.

Measurement of Distance Between Grains

A distance between grains was measured using an area of 500 nm×500 nm asa surface shape in a tapping mode using Nano Scope III manufactured byDigital Instrument as an atom force microscopy (AFM). After theresulting AFM image was subjected to flat treatment, an arbitralcross-section was observed, regarding two adjacent grains havingapproximately same peak heights, a distance between those peaks wasmeasured. In addition, in measurement, a uniform irregular region havingno remarkable recess or projection was measured using a cantilever inthe state where there is no abrasion or stain. The above-mentionedtapping mode is as explained by Q. Zong et al., in Surface ScienceLetter, 1993, vol. 290, L688-690, and this is a method of performingshaking a cantilever having a probe at its tip in the vicinity of aresonance frequency (about 50-500 MHz) using a piezoshaker, and scanninga sample while slightly touching the surface of a sample intermittently,and a method of measuring a two-dimensional surface shape in which aposition of a cantilever was moved in an irregular direction (Zdirection) so that a change in a detected amplitude was maintainedconstant, and a signal based on movement in this Z direction and asignal in a flat plane direction (XY direction). In addition, theabove-mentioned flat treatment is to treat correction of a gradient withone-dimensional, a two-dimensional or three-dimensional function for astandard plane regarding two-dimensional data, and waviness of an entireplane was offset by this treatment.

Then, according to the same manner as that of Example 1-1 except that amaterial and a sintered density of a target, and the film formingconditions (oxygen gas flow rate, TS distance, input electric power)were set as shown in following Table 1, silicon oxide films were formedto manufacture barrier films (Examples 1-2 to 1-5, Comparative Examples1-1 to 1-10). Regarding silicon oxide films of these barrier films,components, a peak position of infrared-ray absorption due to Si—O—Sistretching vibration, a film density and a distance between grains weremeasured as in Example 1-1, and the results are shown in following Table1.

(Measurement of Barrier Property)

Regarding the thus manufactured barrier films (Examples 1-1 to 1-5,Comparative Examples 1-1 to 1-10), an oxygen transmission rate and awater vapor transmission rate were measured under the followingconditions, and the results are shown in following Table 1.

Measurement of Oxygen Transmission Rate

An oxygen transmission rate was measured under the conditions withIndividual Zero Measurement in which background removal measurement wasperformed, at a temperature of 23° C. and a humidity of 90% RH, using anoxygen gas transmission rate measuring apparatus (OX-TRAN 2/20manufactured by MOCON).

Measurement of Water Vapor Transmission Rate

A water vapor transmission rate was measured at a temperature of 40° C.and a humidity of 100% RH using a water vapor transmission ratemeasuring apparatus (PERMATRAN-W 3/31 manufactured by MOCON).

TABLE 1 Film forming conditions Silicon oxide film Barrier propertyOxygen Input Si—O—Si Distance Oxygen Water Target flow TS elec. peakAtomic Film between transmission vapor Density rate distance powerposition ratio density grains rate transmission Barrier film Material(%) (sccm) (mm) (kW) (cm⁻¹) Si:O:C (g/cm³) (nm) (cc/m²/day · atm) rate(g/m²/day) Ex. 1-1 Si 90 20 50 2 1074 100:145:27 2.8 25 0.05 0.05 Ex.1-2 Si 90 30 50 2 1082 100:167:38 2.8 29 0.06 0.08 Ex. 1-3 SiO 90 5 50 21090 100:170:22 2.8 27 0.04 0.09 Ex. 1-4 Si 90 30 50 1.5 1064 100:158:372.7 25 0.02 0.06 Ex. 1-5 Si 90 30 75 1.5 1060 100:143:21 2.6 28 0.080.08 Comp. Ex. 1-1 Si 70 20 50 2 1054 100:141:25 2.5 29 0.75 0.85 Comp.Ex. 1-2 SiO 70 5 50 2 1070 100:165:42 2.5 28 0.62 0.78 Comp. Ex. 1-3SiO₂ 90 0 50 2 1094 100:170:18 2.6 25 0.40 0.93 Comp. Ex. 1-4 SiO₂ 70 050 2 1080 100:168:15 2.4 29 0.35 0.84 Comp. Ex. 1-5 Si 90 40 50 2 1094100:175:45 2.8 33 0.15 0.67 Comp. Ex. 1-6 Si 90 5 50 2 1050 100:113:212.7 22 0.23 0.13 Comp. Ex. 1-7 Si 90 20 25 2 1086 100:160:56 2.9 28 0.150.18 Comp. Ex. 1-8 Si 90 20 75 2 1070 100:145:18 2.8 38 0.28 0.63 Comp.Ex. 1-9 Si 90 20 50 2.5 1082 100:173:38 2.9 21 0.11 0.12 Comp. Ex. 1-10Si 90 20 50 1.5 1068 100:135:23 2.6 35 1.04 1.38

As shown in Table 1, it was confirmed that barrier films (Examples 1-1to 1-5) provided with, as a barrier layer, a silicon oxide film havingan atomic ratio in a range of Si:O:C=100:140 to 170:20 to 40, peakposition of infrared-ray absorption due to Si—O—Si stretching vibrationbetween 1060 to 1090 cm⁻¹, a film density in a range of 2.6 to 2.8g/cm³, and a distance between grains of 30 nm or shorter have theexcellent barrier property (an oxygen transmission rate is 0.1cc/m²/day·atm or less, and a water vapor transmission rate is 0.1g/m²/day or less).

To the contrary, none of barrier films (Comparative Examples 1-1 to1-10) provided with, as a barrier layer, a silicon oxide film having atleast one of, anatomic ratio, a peak position of infrared-ray absorptiondue to Si—O—Si stretching vibration, a film density and a distancebetween grains which are outside of the above-mentioned ranges had theexcellent barrier property (an oxygen transmission rate is 0.1cc/m²/day·atm or less, a water vapor transmission rate is 0.1 g/m²/dayor less).

Example 2 Preparation of Barrier Film

A sheet type biaxially oriented polyethyleneterephthalate film (PET filmA4100 manufactured by Toyobo Co., Ltd., thickness 100 μm) having a sizeof 10 cm×10 cm was manufactured as a substrate film, and this substratefilm was placed into a chamber of a batch-type sputtering apparatus(SPF-530H manufactured by Anelva Corporation), using a corona-untreatedside of the film as a surface on which a film is to be formed. Inaddition, silicon nitride (Si₃N₄) having sintered density of 90%, as atarget material, was mounted in a chamber. A distance between thistarget and a substrate film (TS distance) was set to 50 mm.

Then, an oxygen gas (manufactured by Taiyo Toyo Sanso Co., Ltd. (purity99.9995% or larger)), a nitrogen gas (manufactured by Taiyo Toyo SansoCo., Ltd. (purity 99.9999% or larger)), and an argon gas (manufacturedby Taiyo Toyo Sanso Co., Ltd. (purity 99.9999% or larger)) as a gas tobe added at film formation, were manufactured.

Then, a pressure in a chamber was reduced toultimate vacuum of 2.5×10⁻³Pa with an oil-sealed rotary vacuum pump and a cryo pump. Then, anoxygen gas at a flow rate of 3 sccm and an argon gas at a flow rate of20 sccm were introduced into a chamber, and a pressure in a chamber wasretained at 0.25 Pa by controlling an opening and closing degree of avalve between a vacuum pump and a chamber, and a barrier layercomprising a siliconoxi-nitride film having a thickness of 100 nm wasformed on a substrate film at an input electric power of 1.2 kW by a RFmagnetron sputtering method, to obtain a barrier film (Example 2-1).

Components of the silicon oxi-nitride film formed in the above weremeasured under the following conditions, and a results are shown infollowing Table 2.

Measurement of Components of Silicon Oxi-Nitride Film

Components were measured with ESCA (ESCA LAB 220 i-XL manufactured by VGScientific, England). As a X-ray source, a monochromic Al X-ray sourcehaving the Ag-3d-5/2 peak strength of 300Kcps to 1 Mcps, and a slithaving a diameter of about 1 mm were used. Measurement was performed inthe state where a detector was set on a normal line of a sample surfaceto be measured, and adequate electrification correction was made.Analysis after measurement was performed by using software Eclipseversion 2.1 attached to the above-mentioned ESCA apparatus and usingpeaks corresponding to the binding energies of Si:2p, C:1s, O:1s, N:1s.Upon this, regarding each peak, Shirley's background removal wasperformed, and sensitivity coefficient correction was performed on eachatom (based on C=1, Si=0.817, O=2.930, N=1.800) regarding each peakarea, and an atomic ratio was obtained. Regarding the resulting atomicratio, letting a number of Si atoms to be 100, numbers of O, N, and Catoms which are other components were calculated, and was used as acomponent ratio.

In addition, a maximum peak of an infrared-ray absorbing band due toSi—O stretching vibration and Si—N stretching vibration, a film densityand a distance between grains of a silicon oxi-nitride film formed asdescribed above were measured under the following conditions,respectively, and the results are shown in following Table 2.

Measurement of Infrared Absorbing Spectrum

The infrared absorbing spectrum was measured as in example 1.

Measurement of Film Density

A film density was measured as in example 1 except a ratio of atoms(Si:O=1:2) of a thin film was input as a fitting initial value.

Measurement of Distance Between Grains

A distance between grains was measured as in example 1.

Then, according to the same manner as that of Example 2-1 except that asintered density of a target, and the film forming conditions (oxygengas flow rate, nitrogen gas flow rate, TS distance, input electricpower, and pressure inside the chamber) were set as shown in followingTable 2, silicon oxi-nitride films were formed to manufacture barrierfilms (Examples 2-2 to 2-6, Comparative Examples 2-1 to 2-8). Regardingsilicon oxi-nitride films of these barrier films, components, a maximumpeak of an infrared-ray absorbing band due to Si—O stretching vibrationand Si—N stretching vibration, a film density and a distance betweengrains were measured as in Example 2-1, and the results are shown infollowing Table 2.

(Measurement of Barrier Property)

Regarding the thus manufactured barrier films (Examples 2-1 to 2-6,Comparative Examples 2-1 to 2-8), an oxygen transmission rate and awater vapor transmission rate were measured under the followingconditions, and the results are shown in following Table 2.

Measurement of Oxygen Transmission Rate

An oxygen transmission rate was measured as in example 1.

Measurement of Water Vapor Transmission Rate

A water vapor transmission rate was measured as in example 1.

TABLE 2 Silicon oxi-nitride film Barrier property Film making conditionsSi—O/ Oxygen Water Si₃N₄ Oxygen Input Si—N Distance trans- vapor targetflow Nitrogen TS elec. peak Film between mission transmission Densityrate flow rate distance power Pressure position Atomic ratio densitygrains rate (cc/m²/ rate Barrier film (%) (sccm) (sccm) (mm) (kW) (Pa)(cm⁻¹) Si:O:N:C (g/cm³) (nm) day · atm) (g/m²/day) Ex. 2-1 90 3 0 50 1.20.25 873 100:87:88:37 3.1 23 0.03 0.02 Ex. 2-2 90 0.5 0 50 1.2 0.25 837100:67:66:23 3.1 28 0.05 0.03 Ex. 2-3 90 0.5 10 50 1.5 0.25 833100:71:90:33 3.1 29 0.08 0.02 Ex. 2-4 90 3 0 50 1.2 0.30 881100:85:62:28 2.9 28 0.07 0.09 Ex. 2-5 90 0.5 10 50 1.2 0.20 833100:79:87:35 3.2 28 0.06 0.03 Ex. 2-6 90 3 10 50 1.0 0.25 930100:88:75:30 3.0 27 0.04 0.08 Comp. Ex. 2-1 70 3 0 50 1.2 0.25 893100:65:55:35 2.8 38 0.58 0.51 Comp. Ex. 2-2 90 4 0 50 1.2 0.25 938100:99:58:43 2.9 43 0.24 0.77 Comp. Ex. 2-3 90 0.5 10 50 1.2 0.25 831100:73:78:34 3.1 35 0.15 0.13 Comp. Ex. 2-4 90 3 0 25 1.2 0.25 881100:83:65:53 3.2 33 0.38 0.64 Comp. Ex. 2-5 90 3 0 50 1.5 0.25 843100:70:73:42 3.2 29 0.46 0.58 Comp. Ex. 2-6 90 3 0 50 1.2 0.4 926100:93:55:37 2.8 34 1.17 1.53 Comp. Ex. 2-7 90 0.5 0 50 1.5 0.25 833100:75:88:32 3.3 35 0.93 0.18 Comp. Ex. 2-8 90 0 10 50 1.5 0.25 800100:61:95:35 3.3 38 0.55 0.89

As shown in Table 2, it was confirmed that barrier films (Examples 2-1to 2-6) provided with, as a barrier layer, a silicon oxi-nitride filmhaving an atomic ratio in a range of Si:O:N:C=100:60 to 90:60 to 90:20to 40, a maximum peak of infrared-ray absorption due to Si—O stretchingvibration and Si—N stretching vibration in a range of 820 to 930 cm⁻¹, afilm density in a range of 2.9 to 3.2 g/cm³, and a distance betweengrains of 30 nm or shorter have the excellent barrier property (anoxygen transmission rate is 0.1 cc/m²/day·atm or less, and a water vaportransmission rate is 0.1 g/m²/day or less).

To the contrary, none of barrier films (Comparative Examples 2-1 to 2-8)provided with, as a barrier layer, a silicon oxi-nitride film having atleast one of, an atomic ratio, a maximum peak of an infrared-rayabsorbing band due to Si—O stretching vibration and Si—N stretchingvibration, a film density and a distance between grains which areoutside of the above-mentioned ranges had the excellent barrier property(an oxygen transmission rate is 0.1 cc/m²/day·atm or less, a water vaportransmission rate is 0.1 g/m²/day or less)

Example 3 Preparation of Barrier Film

A winding up-like biaxilly oriented polyethylene terephthalate film (PETfilm A4100 manufactured by Toyobo Co., Ltd., thickness 100 μm) of 30 cmwidth as a substrate film was prepared, and was mounted in a chamber 102of a winding up format dual cathode-type sputtering apparatus 101 havinga construction shown in FIG. 11 so that a corona-untreated surface sideof this substrate film was a surface on which a film is to be formed.This sputtering apparatus 101 is provided with a vacuum chamber 102, asupplying roll 103 a for supplying a substrate film arranged in thisvacuum chamber 102, a winding up roll 103 b, a coating dram 104, apartitioning plate 109, a film making chamber 105 isolated from a vacuumchamber 102 with 109, a target mounting base 106 arranged in this filmmaking chamber 105, an electric source 107 for applying a voltage to atarget, a plasma emitting monitor 108, a vacuum evacuating pump 110connected to a film making chamber 105 via a valve 111, a gas flow ratecontrolling apparatus 112 for controlling a flow rate of a nitrogen gas,and valves 113, 114 for adjusting amounts of an oxygen gas and an argongas to be supplied.

Then, silicon (single crystal, electric resistivity 0.02 Ωcm) as atarget material was mounted on a target mounting base 106 in a filmmaking chamber 105. A distance (TS distance) between this target and asubstrate film was set at 10 cm.

Then, an oxygen gas (manufactured by Taiyo Toyo Sanso Co., Ltd. (purity99.9995% or higher)), a nitrogen gas (manufactured by Taiyo Toyo SansoCo., Ltd. (purity 99.9999% or higher)), and an argon gas (manufacturedby Taiyo Toyo Sanso Co., Ltd. (purity 99.9999% or higher)) as a gas tobe added at film making, were prepared.

Then, a pressure in a vacuum chamber 102 and a film making chamber 105was reduced to ultimate vacuum of 2.0×10⁻³ Pa with a vacuum evacuatingpump 110. Then, an oxygen gas at a flow rate of 0.5 sccm, a nitrogen gasat a flow rate of 50 sccm, and an argon gas at a flow rate of 150 sccmwere introduced into a filmmaking chamber 105, respectively, a pressurein a filmmaking chamber 105 was retained at 0.3 Pa by controlling anopening and closing degree of a valve 111 between a vacuum evacuatingpump 110 and a film making chamber 105, a substrate film was run, and abarrier layer comprising a silicon oxi-nitride film was formed on asubstrate film at an input electric power of 5 kW by a dual magnetronsputtering method, to obtain a barrier film (example A). A running rateof a substrate film was set so that a thickness of a silicon oxi-nitridefilm to be formed became 100 nm.

Then, according to the same manner as that for the above-mentionedexample A except that an electric resistivity of a target, and filmmaking conditions (oxygen gas flow rate, TS distance, input electricpower, pressure in a chamber) were set as shown in the following Table2, silicon oxi-nitride films were formed to prepare barrier films(examples B to F, comparative examples A to F). Regarding siliconoxi-nitride films of these barrier films, components, a position of amaximum peak of infrared-ray absorption due to Si—O stretching vibrationand Si—N stretching vibration, and a distance between grains weremeasured as in example 1, and a film density was measured as in example2. The results are shown in the following Table 3.

(Measurement of Barrier Property)

The thus prepared barrier films (examples A to F comparative examples Ato F) were measured for an oxygen transmission rate and a water vaportransmission rate under the same conditions as those of example 1, andthe results are shown in the following Table 3.

TABLE 3 Silicon oxi-nitride film Barrier property Film making conditionsSi—O/ Oxygen Water Si target Oxygen Input Si—N Distance trans- vaporElectric flow Nitrogen TS elec. peak Film between mission transmissionresistivity rate flow rate distance power Pressure position Atomic ratiodensity grains rate (cc/m²/ rate Barrier film (Ωcm) (sccm) (sccm) (cm)(kW) (Pa) (cm⁻¹) Si:O:N:C (g/cm³) (nm) day · atm) (g/m²/day) Ex. A 0.020.5 50 10 5 0.3 833 100:63:80:32 3.1 25 0.03 0.04 Ex. B 0.02 10 50 10 50.3 873 100:75:78:38 3.1 28 0.05 0.07 Ex. C 0.30 0.5 50 10 5 0.3 833100:61:75:36 2.9 29 0.09 0.08 Ex. D 0.02 10 10 10 5 0.3 930 100:83:65:282.9 27 0.07 0.08 Ex. E 0.02 20 20 10 5 0.3 926 100:88:74:31 3.0 26 0.060.03 Ex. F 0.02 0.5 10 10 5 0.3 845 100:68:62:22 3.2 27 0.05 0.06 Comp.Ex. A 0.5 20 50 10 5 0.3 938 100:95:62:47 3.0 33 0.27 0.30 Comp. Ex. B0.5 0.5 50 10 7 0.3 829 100:68:85:49 3.2 29 0.55 0.42 Comp. Ex. C 0.50.5 50 10 5 0.5 885 100:62:76:35 2.8 38 1.52 2.18 Comp. Ex. D 0.5 0.5 5010 5 0.3 837 100:65:77:24 2.8 27 0.79 0.85 Comp. Ex. E 0.5 0.5 50 10 70.3 833 100:71:72:39 3.0 41 0.53 0.56 Comp. Ex. F 0.5 0 50 4 7 0.3 810100:62:92:35 3.1 25 0.29 0.75

As shown in Table 3, it was conformed that barrier films (examples A toF) provided with, as a barrier layer, a silicon oxi-nitride film havingan atomic ratio in a range of Si:O:N:C=100:60 to 90:60 to 90:20 to 40, amaximum peak of infrared-ray absorption due to Si—O stretching vibrationand Si—N stretching vibration in a range of 820 to 930 cm⁻¹, a filmdensity in a range of 2.9 to 3.2 g/cm², and a distance between grains of30 nm or shorter have the excellent barrier property (an oxygentransmission rate is 0.1 cc/m²/day atm or less, and a water vaportransmission rate is 0.1 g/m²/day or less).

To the contrary, none of barrier films (comparative examples A to F) inwhich at least one of, an atomic ratio, a position of a maximum peak dueto Si—O stretching vibration and SI—N stretching vibration, a filmdensity and a distance between grains is outside the above ranges havethe excellent barrier property (an oxygen transmission rate is 0.1cc/m²/day·atm or less, and a water vapor transmission rate is 0.1g/m²/day or less).

1. A method for manufacturing a barrier film, comprising forming, as abarrier layer, a silicon oxi-nitride film having an atomic ratio ofSi₁₀₀O₆₀₋₉₀N₆₀₋₉₀C₂₀₋₄₀, a maximum peak of infrared-ray absorption dueto Si—O stretching vibration and Si—N stretching vibration is in a rangeof 820 to 930 cm⁻¹, a film density in a range of 2.9 to 3.2 g/cm³ and adistance between grains of 30 nm or shorter, on a substrate film whichis composed of resin, using silicon nitride (Si₃N₄) having a sintereddensity of 60% or higher as a target, in the presence of an oxygen gasby a sputtering method.
 2. The method for manufacturing a barrier filmaccording to claim 1, wherein the sputtering method is a RF sputteringmethod.
 3. A method for manufacturing a barrier film, comprisingforming, as a barrier layer, a silicon oxi-nitride film having an atomicratio of Si₁₀₀O₆₀₋₉₀N₆₀₋₉₀C₂₀₋₄₀, a maximum peak of infrared-rayabsorption due to Si—O stretching vibration and Si—N stretchingvibration in a range of 820 to 930 cm⁻¹, a film density in a range of2.9 to 3.2 g/cm³ and a distance between grains of 30 nm or shorter, on asubstrate film which is composed of resin, using silicon having anelectric resistivity of 0.2 Ωcm or less as a target in the presence ofan oxygen gas and a nitrogen gas by a sputtering method.
 4. The methodfor manufacturing a barrier film according to claim 3, wherein thesputtering method is a dual magnetron sputtering method or a RFsputtering method.
 5. The method for manufacturing a barrier filmaccording to claim 1, wherein a resin layer is provided on the substratefilm in advance, and the barrier layer is formed on the resin layer. 6.The method for manufacturing a barrier film according to claim 3,wherein a resin layer is provided on the substrate film in advance, andthe barrier layer is formed on the resin layer.